In this study, the parametric effects of the EMM process were studied by both numerical simulation and experimental tests. The numerical simulation was performed using commercial software, FEMLAB, to establish a multi-physics model which consists of electrical field, convection and diffusion phenomena to simulate the parametric effects of pulse rate, pulse duty, electrode gap and inflow velocity. From the simulated results, the relationship between parameters and the distribution of metal removal could be established. Proper process variables were also chosen to conduct the EMM experiments. After the experiments, the profile of the processed rectangular slot was measured by a Keyence digital microscope. Comparing profile of the processed rectangular slot with the profile of the cathode, the machining accuracy of EMM process could be determined. It could also verify the goodness of the multi-physics model for predicting machining accuracy. From this study, the effects of parameters such as pulse rate, pulse duty, electrode gap and inflow velocity are better understood. The simulation model could be employed as a predictive tool to provide optimal parameters for better machining accuracy and process stability of the EMM process.